Volare Marcopolo User manual

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CONTENTS
CONTENTS ............................................................................................... 3
INTRODUCTION ...................................................................................... 5
WARRANTY TERM ................................................................................... 7
VOLARE GUARANTEE TERM ..................................................................... 7
VALIDITY PERIOD ..................................................................................... 7
SCOPE ..................................................................................................... 7
CONDITIONS FOR FULL WARRANTY ........................................................ 8
WARRANTY LIMITATIONS ......................................................................... 9
WARRANTY TERMINATION ....................................................................... 11
GENERALITIES ......................................................................................... 11
GENERAL INFORMATION .......................................................................... 12
INSPECTION CHECK LISTS ...................................................................... 13
DELIVERY CHECK LIST – copy to be send to the manufacturer .................. 15
DELIVERY CHECK LIST – customer copy .................................................. 17
INSPECTION AT 5.000 KM ....................................................................... 19
INSPECTION AT 15.000 KM ...................................................................... 21
TECHNICAL DELIVERY INSTRUCTIONS ................................................... 23
PREVENTIVE PERIODIC MAINTENANCE CHART ...................................... 26
PREV.PERIOD.MAINT.CHART - VOLARE W8 AND W9 - ENGINE MWM ....... 27
PREVENTIVE PERIODIC LUBRICATION AND RE-TIGHTENING CHART ....... 32
SPECIFICATIONS ..................................................................................... 34
VOLARE IDENTIFICATION POINTS ............................................................. 34
COMMANDS, CONTROLS AND MAINTENANCE ........................................ 37
PANEL – PANEL IDENTIFICATION .............................................................. 37
OPTICAL WARNING INDICATORS .............................................................. 38
PANEL SWITCHES .................................................................................... 43
INTERRUPTORS ..................................................................................... 44
STARTING SWITCH ................................................................................. 45
MASTER SWITCH .................................................................................... 45
ANTI-FOG COMMAND .............................................................................. 45
AIR CONDITIONER COMMAND ................................................................ 46
SOUND SYSTEM ..................................................................................... 48
SELECTOR SWITCH FUNCTIONS ............................................................. 48
ELECTRIC SWITCHBOARD ...................................................................... 49
MULTIFUNCTIONAL SWITCH .................................................................... 50
SPEED SELECT LEVER – GEARBOX ........................................................ 51
MOTOR HOOD ......................................................................................... 51
ROUTE PLATE ......................................................................................... 51
PARKING BRAKE ..................................................................................... 52
COMMANDS AND CONTROLS ................................................................. 52
DRIVER’S SITE ........................................................................................ 53
PASSENGER COMPARTMENT .................................................................. 55
HEATING SYSTEM ................................................................................... 59
REAR-VIEW MIRRORS .............................................................................. 60
DOORS .................................................................................................... 60
EXTERNAL COVER AND HATCHES .......................................................... 61
BUS BODY PAINTING ................................................................................ 62
EXTERNAL CONSERVATION ...................................................................... 64
INTERNAL CONSERVATION ...................................................................... 65
TOWING HOOK ........................................................................................ 67
GENERAL INSTRUCTIONS ........................................................................ 68
GENERAL SAFETY REGULATIONS ........................................................... 68
CONAMA IMPORTANT PRECAUTIONS ...................................................... 69
FREE ACCELARATION FUMES INDEX ...................................................... 70

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DAILY INSPECTION .................................................................................. 70
IMPORTANT RECOMMENDATIONS FOR DRIVER ...................................... 71
ECONOMICAL DRIVING ......................................................................... 73
INSTRUCTION FOR BREAKING-IN ........................................................... 73
ENGINE STARTING AND STOPPAGE .......................................................... 74
Starting with Cold Engine ......................................................................... 74
Vehicle Starting ........................................................................................ 74
PRECAUTIONS TO BE TAKEN WHEN STARTING THE ENGINE .................... 74
Engine Stoppage ...................................................................................... 76
Parking the Vehicle ................................................................................... 76
PRECAUTIONS FOR REMOVAL A VEHICLE FROM THE SURVICE .............. 76
INSTRUCTIONS, CHECKS AND MAINTENANCE ..................................... 76
SPECIAL PRECATIONS FOR LUBRICATING OIL CHANGES ......................... 76
WEIGHTS AND CAPACITIES ...................................................................... 77
ELECTRIC SYSTEM ................................................................................... 77
Precautions with the Electric System ......................................................... 77
Precautions with Electric Welding ............................................................. 77
Precautions concerning the Alternator operation ........................................ 78
BATTERY ................................................................................................. 78
ENGINE ................................................................................................... 80
Management of the Electromotor MWM .................................................... 80
Electronic Module .................................................................................... 80
Vehicle’s Reaction .................................................................................... 82
Check of the Lubricating Oil Level in the Engine ........................................ 82
Changing of Oil and Lubrication Filter in the Engine ................................... 82
FEED SYSTEM .......................................................................................... 83
Air Feed System Maintenance ................................................................... 83
FUEL SYSTEM .......................................................................................... 85
Fuel Supply System .................................................................................. 85
Fuel Filter ................................................................................................. 85
Fuel Filter Drainage .................................................................................. 86
Low Pressure Fuel System Bleeding ........................................................ 87
Injection System ....................................................................................... 87
Fuel Tank ................................................................................................. 88
COOLING SYSTEM .................................................................................. 89
Radiator ................................................................................................... 89
Cooling System ....................................................................................... 89
Thermostatic Valve .................................................................................. 91
HYDRAULIC CLUTCH SYSTEM ................................................................ 91
Clutch Coupling ........................................................................................ 91
TRANSMISSION – GEARBOX .................................................................... 93
Gearbox – Manual ................................................................................... 93
Gearbox – Automatic ................................................................................ 94
CRANKCASE ............................................................................................ 98
Diferencial Gear ........................................................................................ 98
Pneumatic Suspension ............................................................................. 99
HYDRAULIC STEERING SYSTEM .............................................................. 100
WHEELS AND TYRES ............................................................................... 100
Wheels ..................................................................................................... 100
Tyres ........................................................................................................ 103
Spare Wheel ............................................................................................ 104
BRAKE SYSTEM ....................................................................................... 105
SPECIFICATIONS ..................................................................................... 109
SPECIFICATIONS CHARTS ........................................................................ 109
LUBRICATION CHART – CHART 1 ............................................................. 118
LUBRICATES CHART – CHART 2 .............................................................. 119
RE-TIGHTENING CHART – CHART 3 .......................................................... 119
AUDIO AND VIDEO ELECTRIC DIAGRAM .................................................. 120
AUDIO AND VIDEO ELECTRIC DIAGRAM .................................................. 121
DOOR PNEUMATIC COMMAND ................................................................ 122

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INTRODUCTION
Congratulations! You have just acquired a top quality product designed and built
especially to serve you.
This manual has been prepared to provide you with the information and instructions
that are necessary for the proper operation and maintence of your vehicle, and
also to present the data regarding its specifications.
Read carefully and find out how to operate your vehicle correctly and how to take
proper care of it so as to prolong the service life of your vehicle.
Before operating your vehicle for the first time, read the information contained
in this manual.
The durability of your Volare depends on how you operate it, considering that the
satisfactory performance is the result of your careful and regular operation.
Whenever you need technical assistance, always contact a Volare Representative.
He will be pleased to help you maintain and preserve your Volare and is ready to
offer you all technical assistance you may need.
Finally, we take the opportunity to congratulate you on your choice of the Volare
product, and assure you that we hold a maximum interest in keeping you
satisfied.
Some stay, others Volare!

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WARRANTY TERM
1. VOLARE WARRANTY TERM
1.1. MARCOPOLO S.A. – Volare Division provides a warranty for its products that,
in normal service or operation, got material, workmanship or assembly defects
within the periods and kilometerage specified in this warranty term.
2. VALIDITY PERIOD
2.1. The Volare Product warranty is valid for 12 (twelve) months without limitation
in kilometerage, divided as follows:
• 3 (three) months of legal warrantee;
• 9 (nine) months of contract warrantee, except for the components described in
items 5.1 and 5.16 which are subject to the period in months or in kilometerage,
herewith dominates occurrence of the first.
2.2. The Product Volare warranty is valid since the emission of the tax invoice e
effective delivery to the first customer.
2.3. The Warranty Certificate contains data concerning the first customer and is
annexed to the back cover of the Volare Owner’s Manual.
2.4. The painting is warranted for 24 (twenty four) months against possible defects
related to adherence, shine and resistance, provided that the cleaning is performed
with the products recommended by the manufacturer.
2.5. As for the vehicles equipped with automatic transmission Allison, the warranty
for this unit (transmission) is valid for 36 (thirty six) months without limitation
in kilometerage.
2.6. Wooden floor (Navy-color covering) is warranted for 24 (twenty four) months,
unless improper use is detected.
Here, improper use is understood as usage of current water jets and/or of
water abundantly for cleaning the inner part of the vehicle or use in places with
accumulated water, floods, runnels, rivers and so on.
Similarly, it is strictly prohibited to perform any alteration of the original
characteristics of the vehicle regarding its operation, such as and not only: alteration
of the seats position, new holing in the floor and overweight.
Any other event that is not foreseen in item 2.6 shall be submitted to the
manufacturer’s analysis and decision.
3. SCOPE
3.1. The warranty covers the Volare Product’s parts and components that have
defects or faults in accordance with item 2 (two), except for the described in
item 5.1 and 5.16.
3.2. The warranty covers the manpower, free of charge, corresponding to the
performed services beyond the inspections within the period stated in item 2 (two)
when related to eventual material, workmanship or assembly faults.
3.3. The warranty covers the manpower, free of charge, corresponding to the
performed services during the delivery checks, at 5 000 (five thousand) kilometers
to 15 000 (fifteen thousand) kilometers respectively.

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3.4. The warranty applies to the necessary repairs or replacement of
components with proved material, assembly or workmanship defects. UNDER
NO CIRCUMSTANCES SHALL THE PRODUCT BE REPLACED.
3.5. Any event that is not foreseen in this term shall be submitted to the
manufacture’s analysis and decision.
3.6. The replacement of mechanical, electricil or electronic assemblies/devices of
the vehicle shall be considered only in case of repair impossibility.
4. CONDITIONS FOR FULL WARRANTY
4.1. Perform the preventive inspections established by Marcopolo S.A. – Volare
Division (item “Inspection Checklist”) for this product via the Volare Representatives
network.
4.2. Operate this product adequately, following its specifications and use it for
designated purposes.
4.3. Observe the maintenance and operating instructions prescribed
by MARCOPOLO S.A. – Volare Division and specified in the Owner’s
Manual.
4.4. Do not alter the original structure of this product.
4.5. Use only busloads and cargos that do not exceed the limits specified by
MARCOPOLO S.A. – Volare Division.
4.6. Allow only legally authorized people to drive this vehicle.
4.7. Use only adequate fuel and lubricants recommended by MARCOPOLO S.A.
– Volare Division.
4.8. Require and execute inspections and services only at the Volare
Representatives.
4.9. Do not damage seals of the tachograph and/or of the gearbox.
4.10. Observe the limits of kilometerage set to perform planned preventive
inspections:
• At delivery – On the occasion of the sale;
• At 5 000 (five thousand) km: between 4 000 (four thousand) and 6 000 (six
thousand) km;
• At 15 000 (fifteen thousand) km: between 14 000 (fourteen thousand) and 16
000 (sixteen thousand) km.
4.11. After the inspection at 15 000 (fifteen thousand) kilometers, there should be
performed planned preventive and paid inspections at 30 000 (thirty thousand)
kilometers, with intervals of 10 000 (ten thousand) kilometers.
4.12. The planned maintenance during the inspections, either free of charge or
no, with different kilometerage of the specification given in the maintenance and
lubrication chart, shall be performed at a Volare Representative Office.
4.13. This warranty does not cover manpower of the performed services during
the paid periodic inspections, as the item “Inspection Checklists” informs.

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• IF ANY OF THE INSPECTIONS IS NOT PERFORMED, IT AUTOMATICALLY
CANCELS THE PRODUCT WARRANTY.
5. WARRANTY LIMITATIONS
5.1. Defected parts or components replaced under warranty become the
property of MARCOPOLO S.A. – Volare Division.
5.2. The warranty attends to possible material, workmanship and assembly
faults appeared during the product construction processes, provided that the
manufacturer is responsible for the repairment via the Volare Representatives
network, with the replacement of the original parts or components or service
rendering for the purpose of the anomaly correction.
5.3. Any fault in the electronic system (electronic module, sensors and
actuators) occurred because of non-observance of the measures mentioned
in the Volare Owner’s Manual, and/or the replacement of the electronic module
occurred due to incorrect diagnosis, are not covered by the warranty. If, to
check the electronic module for faults, are used diagnostic instruments of
different from MWM/BOSCH brands, the warranty does not cover it as well.
5.4. Windshield, rear screen, side fixed or slideable windows, mirrors, lights
and lamps are under warranty in terms of workmanship and/or assembly
defects for 90 (ninety) days since the date of the tax invoice emission for
the first customer.
5.5. Lamps, fuses, starters, control switches, coils/solenoid valves, diodes,
micro-switches enter into composition of parts with determined period of
service, having the term covered by the warranty of 90 (ninety) days since
the date of the tax invoice emission for the first customer.
5.6. Repairs of pneumatic cylinders, repairs of pneumatic valves, pneumatic
valves in general, electric motors, windshield wipers, roof exhauster,
heating/defroster blowers, air condition blowers in the overhead luggage
rack, windshield washer motor, door bushings, door guide pieces, door
brushes, door pivots and terminals are the parts of normal wear, with the
warranty limitation of 6 (six) months since the tax invoice emission for the
first customer.
5.7. The parts and components, undergone natural wear, should be replaced
according to the use of the vehicle, at the owner’s costs, unless a material,
workmanship or assembly defect is detected within the warranty term specified
in item 2 (two).
5.8. List of the parts considered as normal wear parts and assemblies:
Pneumatic: Tyres, protectors and air chamber.
Suspension: Shock absorbers, springs, bushings and pins.
Transmission: Clutch plate, crosspiece, antifriction bearing, joint
sleeves of crankcase and collars in general.
Brake system: Brake shoe lining, drums, pads and disks.
Electric system: Alternator, starting motor and battery.
Bus body: Floor covering, door mechanism, felts and
windscreen wipers mechanism, windscreen
wipers, defroster, window and route chart felts.
Air conditioner: Filters, belts, gas charge, ventilators, controls
and collars in general

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5.9. From this warranty are excluded expenses related to the following items of
maintenance:
• Steering alignment and wheel balancing;
• Junctions in general, addition of water to the radiator and fan belts;
• Air filtration elements, lubricant oil and air conditioner;
• Oils, greases and solutions;
• Testing and regulations;
• Replacement of brake pads and shoe lining;
• Regulation of brake system, coupling clutch and repairs in general;
• Gas charge (Air conditioner).
5.10.
This warranty applies only to the vehicle, its parts and components,
not covering expenses for towing, transporting, parking of the vehicle or
personal expenses, such as: telephone calls, accommodation, etc. , and
also emergent damages and lost, direct, indirect or third parties profits; and
is limited with the vehicle repair, replacement or repairment of its parts and
components.
5.11. The expenses for transportation of the Volare Representative or Service
Station to the vehicle and from the vehicle to the site of the Volare Representative
or Service Service are not covered by the warranty.
5.12. The parts that have defects because of application of other inauthentic
parts a
nd/or components with different technical performance are excluded
from the warranty according to the specifications of MARCOPOLO S.A. – Volare
Division.
5.13. The warranty does not cover equipment or alterations made and applicated by
third parties that were not authorized by MARCOPOLO S.A. – Volare Division.
5.14. Replacement of defected parts or components by new ones or services
performed within the product warranty term do not imply an extension of the
original product warranty validity described in item 2 (two).
5.15. The warranty does not cover the defects occurred because of prolonged
operation, all types of accidents, emergencies or force majeure.
5.16. The components: tyres, battery, alternator, starting motor, turbo-supplier,
hydraulic steering system, tachograph, radio, CD, air conditioner, video and monitor
are covered by the respective manufacturers’ warranty. They have to be directed
to a Volare Representative or Service Station that redirect them to the Authorized
Representatives of the component manufacturer, which provide the respective
warranty, provided that are observed the validity terms stipulated in item 2 (two)
and especially concerning the following items:
5.16.1. High-pressure pump and electronic injectors, starting motor and alternators
that are limited by the warranty for 12 (twelve) months or 50 000 (fifty thousand)
kilometers, herewith dominates occurrence of the first;
5.16.2. Hydraulic steering system, limited by the warranty for 12 (twelve) months
or 100 000 (hundred thousand) kilometers, herewith dominates occurrence of
the first;
5.16.3. Compressor of the air conditioner and its support, limited by the warranty

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of 12 (twelve) months or 100 000 (hundred thousand) kilometers.
5.17. Decoloration or alteration of the painting because of an inadequate use or
normal or accidental wear of the product are excluded from the warranty.
5.18. Only the Volare Representatives are authorized to render service under
warranty;
5.19. The warranty of the replaced parts, under warranty within the period specified
in item 2 (two), is similar to the present warranty term of the vehicle;
5.20. After the end of the vehicle’s warranty, the warranty for the parts, acquired
at a Volare Representative Office and replaced in its installations, is 6 (six)
months.
6. WARRANTY TERMINATION
6.1. When the validity term described in item 2.1 expires.
6.2. Within the term specified in item 2.1, there is stated the non-observance of
the established conditions in this warranty term mainly disposed in items 4.1
to 4.13.
6.3. The warranty for the structure of the product will cease:
6.3.1. If there are made alterations in the original suspension system of the
chassis;
6.3.2. If the vehicle has damaged components in the suspension system and/or
if the components have been moved out (shock absorbers, stabilizers, springs,
etc.);
6.3.3. If there are hollows on the underbody;
6.3.4. If the vehicle got into an accident or collision;
6.3.5. If the structure of the vehicle was repaired or altered not in one of the
Volare Representatives;
6.3.6. If the vehicle was transported loads, exceeding the stipulated weight limit;
6.3.7. If there are detected installations of inauthentic parts;
6.3.8. Due to non-observance of the manufacturer’s instructions;
6.3.9. Due to untimely execution of all and/or any inspections established in the
Owner’s Manual at one of the Volare Representatives.
7. GENERALITIES
7.1. MARCOPOLO S.A. - Volare Division reserves the right to perform modifications
or/and improvement of its projects.. This does not oblige it to apply them to the
previously fabricated products.
7.2. Some options should be required during the sale of the vehicle, and
MARCOPOLO S/A – Volare Division reserves the right to alter the cost, chart of
offers, specifications, serial equipments and/or any other options of the products,
at any moment and without notification. Some items, mentioned it the present
manual, vary, depending on model and version of the chosen vehicle.
7.3. The present WARRANTY TERM applies exclusively to the Volare products.
MARCOPOLO S.A. – Volare Division is not responsible for the commitments
assumed by third parties that differ from this WARRANTY TERM.

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7. 4. MARCOPOLO S.A. – Volare Division recommends consumers of its products
that, for obtaining a full warranty, they should consult a Volare Representatives
and the Owner’s Manual with respect to the correct and adequate operation of
this product.
7.5. The figures given in this manual are merely illustrative. MARCOPOLO
S/A – Volare Division reserves the right to demonstrate in the owner’s
manual optional illustrations without assigning any obligation of applying
them to the commercial products without an appropriate specification at
the act of sale.
GENERAL INFORMATION
• To start using this product, first read attentively the Volare Owner’s Manual.
It contains important information on the use and adequate conservation of your
product.
• The Volare Owner’s Manual always should accompany the product. The
manual comprises INSPECTIONS CONTROL, WARRANTY CERTIFICATE,
TECNHICAL DELIVERY CHECKLIST, WARRANTY TERM, INSPECTION STUBS and
APPROPRIATELY WRITTEN MANUAL.
• CONTROL CHART OF INSPECTIONS is intended for recording of the inspections
of your product, to guarantee its right to the WARRANTY and for the proper control
of the product maintenance as well.
• THE CERTIFICATE OF WARRANTY properly filled and authorized by a Volare
Representative, besides identification of your vehicle, is primarily intended for
granting the right to the WARRANTY.
Require from your Volare Representative the proper filling of the DELIVERY CHECK
LIST, the document that guarantees your rights to the WARRANTY, when signed
by you and registered by the manufacturer.
• The WARRANTY TERM comprises the contract information that ensures you
the access to any Volare Representative. It refers to the maintenance of parts and
service within the terms under WARRANTY, established in it.
• The INSPECTION STUBS contain the information on maintenance that should
be followed in the periods indicated in them. Proper filling of the stubs ensures
you the Right to the Warranty according to the Warranty Term.
• In the course of the Delivery Inspection require the verification and clarification
concerning the items specified in the item “Technical Delivery Instructions” and
“Delivery Check List”.
• You are fully responsible for delivery of your vehicle and for fulfillment of
inspections at one of the Volare Representatives Offices.
•
Always contact a Volare Representative to execute the services under warranty.
• Volare Representatives are authorized to render Technical Assistance to the
client. Get in touch with them whenever you find it necessary to resolve your
doubts about operation, maintenance, specifications, application and other points
concerning your Volare product.
• Attentively follow the instructions stated in the maintenance chart in the manual’s
appendix. Operating life of your product depends on the frequency of the described
items fulfillment within the periods specified in the chart.
• When your product undergoes occasional problems, regardless of the inspection
period, immediately contact one of the Volare Representatives to solve them.

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INSPECTION CHECK LISTS
To preserve the right to the vehicle’s warranty, it is obligatory to perform periodic
inspections at the Volare Representatives in the specified intervals.
The check of the maintenance chart execution is made by virtue of the
authentification by the executive Representative of the respective check of
periodical inspections.
Chassis no.
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Record of
Technical Delivery
Delivery date
Mileage (Km)
Volare
Representative’s Code
Volare
Representative’s Stamp
RECORD OF TECHNICAL DELIVERY - Copy to be sent to the Manufacturer
Label: Mileage (km): Volare Model:
Chassis no.: Engine No:
Owner:
Address: No.:
District: Zip Code: Telephone:
City: State: e-mail:
Delivery Date: Trade Note No.:
Volare Representative’s Code:
Person responsible for Technical Delivery (Name and Signature):
Volare Representative’s Stamp:
Herewith I declare that this vehicle has been delivered to me, this day, completely inspected and in perfect external and operating
conditions. I have also received orientation concerning the Warranty Term, inspections and instructions stated in the Owner’s Manual
that describe the vehicle operation and maintenance and in the item Instructions for Technical Delivery, realizing that non-observance
of the operational procedures guidelines shall result in immediate cancellation of the product warranty.
Customer’s Legible Name and Signature

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Record of
Technical Delivery
Delivery date
Mileage (Km)
Volare
Representative’s Code
Volare
Representative’s Stamp
RECORD OF TECHNICAL DELIVERY - Customer Copy
Label: Mileage (km): Volare Model:
Chassis no.: Engine No:
Owner:
Address: No.:
District: Zip Code: Telephone:
City: State: e-mail:
Delivery Date: Trade Note No.:
Volare Representative’s Code:
Person responsible for Technical Delivery (Name and Signature):
Volare Representative’s Stamp:
Herewith I declare that this vehicle has been delivered to me, this day, completely inspected and in perfect external and operating
conditions. I have also received orientation concerning the Warranty Term, inspections and instructions stated in the Owner’s Manual
that describe the vehicle operation and maintenance and in the item Instructions for Technical Delivery, realizing that non-observance
of the operational procedures guidelines shall result in immediate cancellation of the product warranty.
Customer’s Legible Name and Signature

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1919
5,000 Km
Overhaul
Delivery date
Mileage (Km)
Volare
Representative’s Code
Volare
Representative’s Stamp
5,000 Km Overhaul - Free-of-charge Labour - Copy to be sent to the Manufacturer
Label: Mileage (km): Volare Model:
Chassis no.: Engine No:
Owner:
Address: No.:
District: Zip Code: Telephone:
City: State: e-mail:
Overhaul Date: Trade Note No.:
Volare Representative’s Code:
Person responsible for Technical Delivery (Name and Signature):
Volare Representative’s Stamp:
I hereby declare that I have been assisted in every item of the 5,000 Km Overhaul contained in the Periodical Preventive Maintenance
Chart of the Owner`s Manual.
Customer’s Legible Name and Signature

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